Method of forming buildings



April 1, 1969 v. BEN-AZIZ 3, 3

' METHOD OF FORMING BUILDINGS Filed April 11, 1966 She st of 2 FIGJ .INVENTOR. o 43 44 v/croe BE/v-Az/z v Arr-021x45) April 1,1969 v. BE-Az|z I 3,435,583

METHOD OF FORMING BUILDINGS Filed Aprii 11, 1966 v Sheet 3 of2 FIGZJFIG.7

I NVENTOR.

11/0702 Bew-Az/z United States Patent US. Cl. 52-745 2 Claims ABSTRACTOF THE DISCLOSURE The specification of this application teaches a methodof forming buildings in which a core structure is erected such thatsteel members incorporated in the structure are exposed at its exteriorsurface. Cranes or other lifting means are provided on that corestructure for lifting heavy loads. Structures which will become floorsof the building are assembled at the base of the core structure suchthat they encompass the core and are made of steel in regions adjacentthe core. The floor structures are then lifted into place and afiixedtemporarily to the core structure. Each floor is adjusted so that thatportion of the floor which is adjacent the core structure is level. Thefloor is then secured, employing a metal to metal connection, to thecore structure. Columns are erected at the margins of the floors andeach floor is adjusted so that it is level in the regions of its outerperiphery and is then fixed to the columns. An exterior wall structureis erected by attaching wall and window panels to the several floors.The several fioors are completed by applying layers of sheet steel andconcrete to them.

The number of building units may be multiplied by creating separate corestructures and floors for each building unit and by interconnecting thefloors of the several units.

The present invention relates generally to methods of forming buildings,and more particularly to mass production procedures for constructingbuildings in a quick and eflicient manner.

The art of constructing homes and other types of buildings, includingindustrial and oifice buildings, is extremely old, since shelter was oneof the first items that man provided for himself. The methods employedin constructing buildings have not changed as markedly as have othertechnological industries. For instance, buildings have generally beenbuilt floor by floor commencing at the ground level. Such procedurebegins with the foundation and each succeeding floor is successivelyplaced thereon.

Additionally, the methods employed in fastening different structuralmembers together have not changed appreciably over the years, thusnecessitating considerable manual labor in the formation of a buildingstructure.

It has been deemed desirable for a number of years to change the methodof constructing buildings so as to erect it at a much faster rate andthereby cause it to be less expensive though as efiicient as present daybuildings. Also, it has been deemed desirable to provide, in such methodof construction, considerable flexibility such that the buildingcontractor can construct virtually any size or shape building desired.

In view of the foregoing, it is an object of the present invention toteach a method of constructing buildings and the like whereby the samemay be produced at a fast rate according to mass production methods.

Another object of the present invention is to teach a method ofconstructing buildings and the like as characterized above wherein acentral core structure is initially provided and from whichsubstantially all of the floors are raised into proper location.

Patented Apr. 1, 1969 ICC Another object of the present invention is toteach a method of forming buildings and the like as characterized abovewherein the core structure is slip-formed of con crete and is providedwith vertical steel columns to which the various steel floors arerigidly affixed in proper position.

A still further object of the present invention is to teach a method offorming buildings and the like as characterized above which includesarranging a plurality of such core structure in predetermined spacedrelation and constructing the floors about each of them so that severalbuilding modules are thereby arranged in predetermined relation to beconnected together to form a single composite building.

A further object of the present invention is to teach a method offorming buildings and the like as characterized above which is simpleand inexpensive to practice and which provides a rugged and dependablebuilding, with a high degree of resistance to lateral loads during andafter construction. This and other objects and advantages of theinvention are realized in part by erecting a core structure, providingmeans on the core structure for lifting heavy loads, assembling floorsfor said building on the ground and lifting said floors to the desiredelevation and then firmly attaching the floors to said core at thedesired individual elevation.

The novel features which I consider characteristic of my invention areset forth with particularly in the appended claims. The inventionitself, however, both as to its organization and mode of operation,together with additional objects and advantages thereof, will best beunderstood from the following description of specific embodiments whenread in connection with the accompanying drawings, in which:

FIGURE 1 is a fragmentary top plan view of a building under constructionaccording to the present invention, showing several alternative methodsfor raising the floor structures into place;

FIGURE 2 is a side elevational view showing the method steps of FIGURE1;

FIGURE 3 is a fragmentary side elevational view of a building accordingto the present method of construction;

FIGURE 4 is a fragmentary horizontal sectional view, taken substantiallyalong line 44 of FIGURE 2 of the drawings;

FIGURE 5 is a sectional view, taken substantially along line 55 ofFIGURE 4;

FIGURE 6 is an enlarged fragmentary view of a portion of FIGURE 1;

FIGURE 7 is a sectional view taken substantially along line 77 of FIGURE6;

FIGURE 8 is an enlarged fragmentary view of another portion of FIGURE 1;and

FIGURE 9 is a sectional view, taken substantially along line 99 ofFIGURE 8.

Like reference characters indicate corresponding parts throughout theseveral views of the drawings.

Referring to FIGURES l and 2 of the drawings, there is shown thereinmany of the steps of the basic method of forming a building according tothe present invention.

Initially, a core structure '20 is provided, formed of both concrete 22and steel 24. Such method may employ virtually any manner forconstructing the core structure 20, and such core structure may beformed of virtually any desired materials. For instance, it has beenfound that such core structure may be formed of concrete byslip-forming. Additionally, there may be provided one steel box column26 at each of the four corners of the core structure.

As will be readily apparent to those persons skilled in the art, thecore structure 20 may be formed in virtually any desired shape. Forinstance, it is contemplated that such core structure might constitutethe housing for one or more elevator shafts of the finished building,and it may include suitable storage areas or lavatories and the like.

In any event, the core structure 20 is ultimately provided to thedesired height, above the intended top most level of the proposedbuilding.

Thereafter, suitable footings as shown at 28 are provided in the groundto support various vertical columns to be hereinafter erected. Suchfootings may be formed immediately following the construction of thecore structure or they may be provided at any time prior to the erectionof such columns thereon, as will be readily apparent to those personsskilled in the art.

As shown in FIGURE 2 of the drawings, the next step in the method offorming a building according to the present invention, may varyaccording to the desires of the particular contractor. For instance, asshown in the left-hand portion of FIGURE 2 of the drawings, a pluralityof steel floor structures 30 may be formed about the core structure 20in proper horizontal placement with respect thereto. It is contemplatedthat such floor structures 30 may be partially or wholly fabricated in asteel shop removed from the building site or they may be fabricatedbeneath and about the core structure 20 as shown.

In the alternative, it is contemplated that a platform 32 (right-handportion of FIGURE 2) having vertical support members 34 may be providedwhereon the floor structures 30 are formed. Such platform 32 is, ofcourse, elevated from ground level and completely surrounds the corestructure 20 to enable workmen to effect the proper fabrication of thefloor structures or portions ther of as the case may be.

As shown in FIGURE 1 of the drawings, each floor structure 30 is formedwith suitable exterior longitudinal and transverse structural member 36,38, 40, and 42 which are Welded together in a rectangular shape.Suitable interior longitudinal structural members 44 and 46 are providedat one end of the floor structure, and corresponding structural members48 and 50 at the other end. Suitable interior transverse structuralmembers 52, 54, 56 and 58 are also provided as well as partialtransverse members 60, 62, 64, 66, 68, 70, 72 and 74. A connectingmember 76 ties all of the partial transverse members 60, 62, 64 and 66together, while a corresponding member 78 ties together the members 68,70, 72 and 74. Suitable corner plates 80, 82, 84 and 86 are used toconnect the various corner structural members together as shown mostclearly in FIGURE 1 of the drawings.

It is contemplated that the floor structure 30 may be formed of anyappropriate structural members such as I-beams, H-beams and the like.However, it has been found most appropriate to employ steel beams havingI-sections to afford the necessary compression, bending, tensile andshear strengths.

All of such members are preferably welded together according to the bestknown present day practices to provide a unitary structure. It is,however, contemplated that the present invention is not limited to theuse of steel members and that in the event other materials were to beused, the appropriate bonding or connecting means for such materialwould be used.

As also shown in FIGURE 1 of the drawings, the lefthand portion thereofshows a winch 88 having a rotatable pulley 90 associated therewith. Aline or cable 92 cooperates with such pulley 90 and with an idler pulley94 suspended beyond the side of core structure 20 by means of a steelframe 96. Such cable is bifurcated as at 98 to provide a pair of a cableportions 100 and 102 which are attached to opposite sides of a floorstructure 30.

An alternative method is shown in the right-hand portion of FIGURE 1,and comprises a winch 104 having a rotatable pulley 106 and a pair ofidler pulleys 108 4 and 110 suspended from the core structure by members112 and 114. Suitable cable 116 is provided for cooperation with both ofthe pulleys 108 and 110 as shown in the drawings.

It is contemplated that the winch 104 may be positioned on the corestructure in a manner similar to the placement of winch 88 as aboveexplained, or winch 104 may be positioned at ground level adjacent thecore structure as shown most clearly in FIGURE 2. Thus, the action ofwinch 104 can be to lift the various floor structures as willhereinafter be described, irrespective of its position on the corestructure or ground.

The winches 88 and 104, as well as the components associated therewith,are merely for purposes of illustration, it being realized that variousforms and styles of pulling or hauling devices may be employed withinthe context of the present invention. In fact, it is contemplated withinthe present invention that external hoist means such as a separatederrick or the like may be employed.

The various prefabricated floor structures 30 are then hoisted intoproper elevation as shown most clearly in FIGURE 2. The above describedwinches 88 and 104 or any combination thereof, may be used to accomplishthis. The upper-most floor structure is hoisted first.

As shown most clearly in FIGURE 4 of the drawings, the columns 26 may beformed in a box-section and may be connected to the reinforcing steel 23embedded in the concrete core structure. Such reinforcing steel may bewelded to the columns 26, and the columns themselves may be formed bysteel plate welded together in the desired configuration. As shown mostclearly in FIGURE 5 of the drawings, the individual floor structures 30may be initially and temporarily positioned adjacent the core structureby any appropriate means such as support bar 118 and adjusting wedges orshims 120. As shown, the support bar 118 fits within a suitable openingformed in column 26 to rest against the undersurface of a horizontalplate 26a. The wedges or shims 120 are then placed on bar 118 to supportthe adjacent corner of the floor structure 30. The height of the floorcan then be adjusted by sliding the shims or wedges 120 toward or awayfrom each other.

After all four corners of the floor structure have been suitablytemporarily supported, as shown in FIGURE 5 of the drawings, permanentfastening means may be provided. A plate 122 welded to the side ofcolumn 26 may be bolted, riveted or welded to the floor structure 30 asshown in FIGURE 5. Also, an upper plate 124 and a lower plate 126 may bewelded in position between the floor structure and the box column 26 asalso shown therein. Whereas the upper plate 124 is smaller in width thanthe adjacent flange of the I-beam of the floor structure, the lowerplate 126 should be larger than its adjacent flange to permit of weldingfrom the top.

After the various interior corners of the floor structures 30 have beenpermanently anchored in place as shown, the temporary support means canbe removed. In fact, as will be readily apparent, such temporary supportmeans should be removed after plates 122 and 124 are in place to provideaccess to the space required for plate 126. Such temporary support meansis removed merely by separating the wedges or shims 120 so as to freethe support bar 118.

Thereafter, succeeding lower floors of the building can be anchored tothe core structure in like manner. Thus, there is provided a series offloor structures arranged along the core structure.

The perimeters on outer marginal edges of the various floor structuresare then connected to suitable support columns. Such columns are shownat 128 and may take any desired form such as I-beams or H-beams as iswell understood in the art. Such vertical columns are suitably anchoredon and to the appropriate footings 28 as shown in FIGURE 2 of thedrawings.

With the columns 128 in proper position, the individual floor structures30 are leveled by means of the winches 88 and 104 or any otherappropriate hoist means. With the perimeter of each floor at the properelevation, the

Y floor structures are then welded firmly to the support columns 128.The particular manner employed in tying the floors to the supportcolumns may vary, but several of such methods are shown in FIGURES 6-9,inclusive.

FIGURE 6 is an enlarged fragmentary Niew of the connection between oneof the support columns 128 and the longitudinal exterior structuralmember 36 of one of the floor structures. The transverse structuralmember 60 may have its end portion formed such as to fit within the sideof I-beam 36. While in such position, the two structural members arefirmly welded together along all mating surfaces and edges. Then, thelongitudinal structural member 36 is firmly welded to the verticalcolumn 128 as shown in FIGURES 6 and 7. This then provides a strong firmconnection between all of the members, as well as the vertical column128. A supporting gusset or flange member 130 may be employed beneaththe horizontal member 36 as shown most clearly in FIGURE 7.

The connection between a side vertical column 128 and a transverse sidemember such as members 38 and 42, is shown most clearly in FIGURES 8 and9' of the drawings. Here, it may be desirable to extend the longitudinalmember beyond the transverse member with the transverse memberterminating in the side contour of the longitudinal member. That is, thetransverse member 42 is formed in predetermined lengths or sections,each of which has its opposite end portions contoured to fit the side ofthe I-beam of the various longitudinal support members. Such sectionsare then welded at the positions shown most clearly in FIGURES 8 and 9.

With the perimeter of the particular floor structure 30 raised to theproper elevation, the end of the longitudinal support member 44 iswelded to the adjacent Vertical column 128. As shown in FIGURE 9 of thedrawings, side plate 130 is provided on one side of the web of thelongitudinal support member 44, such plate being welded to both thevertical column and the longitudinal support member.

Thereafter, steel deck 132 is welded to the upper flanges of the variousfloor structures 30' and lightweight concrete to the desired depth ispoured thereon as shown at 134. In this way, strong firm floors areprovided for the building.

It is also contemplated within this invention that the floors of thebuilding might be completed, including partition walls and othercomponents, before they are lifted into place. In fact, any desireddegree of completion can be made to the floors before being raised,limited only by the size and strength of the winches or other hoistmeans.

It may be found desirable as shown most clearly in FIGURE 3 of thedrawings to tie together the upper ends of the various vertical supportcolumns 128. In FIGURE 3 one such horizontal tie member is shown at 136.

As also shown in FIGURE 3 of the drawings, suitable curtain wallstructure can thereafter be attached to the edges of the floors toprovide the exterior facade for the building. Such curtain wallstructure includes suitable mullions and sills, as well as wall andwindow panels to provide a lightweight but weather resistant exteriorfor 6 the building. The building shown in FIGURE 3 of the drawingsfurther includes a penthouse on the upper most floor of the building.Also, additional side structures as shown at and 142 may be providedafter the main part of the building has been erected.

It is contemplated that the aforedescribed method of constructing asingle building structure may be employed to build a structurecomprising many such individual units. That is, it is contemplated thatseveral building modules may be provided each having its own corestructure and its own floor structure thereabout. The adjacent floorstructures are then connected together as by welding, riveting, boltingor the like to provide a long complex of buildings arranged in acontiguous manner.

It is thus seen that the present invention teaches a method of forming abuilding structure which is capable of providing a firm sturdy structurein a quick and efficient manner.

Although I have shown and described certain specific embodiments of myinvention, I am fully aware that many modifications thereof arepossible. My invention, therefore, is not to be restricted exceptinsofar as is necessitated by the prior art and by the spirit of theappended claims.

Iclaim:

1. The method of forming a building comprising the steps of, erecting ahollow core structure having steel vertical columns accessible at theexterior thereof, providing means on said core structure for liftingheavy loads, assembling floors for said building on the ground aboutsaid core structure having steel portions accessible at the interiormargins of said floors adjacent said core structure, lifting said floorsby said means to the desired elevation, temporarily fixing said floorsto said core structure, leveling said floor in regions adjacent saidcore structure by use of wedges, thereafter permanently fixing saidfloors to said columns by welding said steel interior margins of saidfloors to said steel vertical columns of said core structure, providingvertical columns about the perimeter of said building, leveling saidfloors about said perimeter and attaching same to said perimetercolumns, and securing exterior wall structure for said building to saidfloors about the perimeter of said building.

2. The method of forming a building according to claim 1, including thefurther step of pouring concrete on each of said floors to provide thedesired strength and rigidity thereof.

References Cited UNITED STATES PATENTS 3,199,259 8/1965 Long 527452,675,895 4/1954 Loewenstein 52236 2,871,544 2/1959 Youtz 527452,964,143 12/ 1960 Fayeton 52745 3,038,568 6/1962 Morgan 52236 3,058,26410/1962 Varlonga 52236 3,156,071 11/1964 Van Bijlevelt 52745 3,251,1672/1966 Curran 52688 3,254,466 6/1966 Von Heidenstam 52745 3,260,0287/1966 Fraser 52745 3,295,288 1/1967 Bakke et al. 52741 3,302,363 2/1967Frey 52745 FRANCIS K. ZUGEL, Primary Examiner.

